Solutions of Exercises PN381 00137360001303911569

Vacuum technology – Fundamentals
Training course
Solutions
of
exercises
1
Festo
Didactic
2 © Festo Didactic GmbH & Co. KG

Solution of exercise 1: Generating vacuum
Edition: 10/2010
Authors: Ralph-Christoph Weber
Editor: Frank Ebel
Graphics: Ralph-Christoph Weber
Layout: 01/2011, Susanne Durz, Frank Ebel
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2011
Internet: www.festo-didactic.com
E-mail: did@de.festo.com
The copying, distribution and utilization of this document as well as the communication of
its contents to others without expressed authorization is prohibited. Offenders will be held
liable for the payment of damages. All rights reserved, in particular the right to carry out
patent, utility model or ornamental design registration.
© Festo Didactic GmbH & Co. KG 3

Contents
Solution of exercise 1: Generating vacuum 4

Solution of exercise 2: Selecting suction cups for various workpieces 12
Solution of exercise 3: Maintaining vacuum when using more than one suction cup 22
Solution of exercise 4: Monitoring partial vacuum 30
Solution of exercise 5: Reducing compressed air consumption in a vacuum system 38
Solution of exercise 6: Controlled release of workpieces retained by a vacuum 44

Solution of exercise 1
Generating vacuum
Learning objectives
After completing this exercise:
 You’ll be able to generate a partial vacuum.
 You’ll be familiar with the function of a venturi nozzle.
 You’ll be familiar with the effects of system pressure on the degree of vacuum
achieved and on the evacuation time with different vacuum generators.
 You’ll be familiar with the effects of throttle points on vacuum generation.
 You’ll be able to control and adjust vacuum.
Problem description
A handling unit for different workpieces needs to be developed. Your job is to examine
various components and investigate the possible use of vacuum technology. First of all,
you’ll have to examine components used for vacuum generation.
Parameters
• Use the vacuum generators included in the equipment set.
Project assignment
1. Describe the mode of operation of a vacuum generator.
2. Set up the test circuit.
3. Measure the vacuum generated and the evacuation time with various vacuum
generators.
4. Draw characteristic curves for both vacuum generators.
5. Compare the two vacuum generators and describe their differences.
6. List any possible negative effects on vacuum generation.

Mode of operation of a vacuum generator based on the venturi principle
– Name the various components and ports of the vacuum generator shown below. Enter
the corresponding designations to the right of the numbers in the table.
Exhaust port, supply port, collector nozzle, jet nozzle, vacuum port
Vacuum generator
Number Designation
1 Supply port
2 Jet nozzle
3 Collector nozzle
4 Exhaust port
5 Vacuum port
– Describe the mode of operation of the vacuum generator based on the venturi
principle.
Compressed air flows from the supply port (1) through a restriction, i.e. the vacuum
generator’s jet nozzle (2). Air flow velocity is increased at this restriction to
ultrasonic speeds. After the air exits the jet nozzle, it expands and flows through the
collector nozzle (3) and out of the exhaust port (4). Partial vacuum occurs in the
chamber around the jet nozzle during this process. As a result, air is drawn in
through the vacuum port.

Measuring the degree of partial vacuum generated with various vacuum

generators
Set up the controller in accordance with the circuit diagram shown below. Measure the
degree of partial vacuum achieved with the vacuum generator at different system
pressures. Compare the two vacuum generators included in the equipment set.
– Enter the acquired values in the table below.
1V3
+2 4 V 1 2 3 1 3
13 12 14 22 24
1V2 1Z1
S1 K1 K1
14 11 21
2
31
S2 1 3
32
1V1 2
A1 1M 1
K1 1M 1 1 3
A2
0 V 12
11 14 .2
22
21 24 .3
32
31 34
42
41 44
Vacuum generator VN-05-H-T3-PQ2-VQ2- Vacuum generator VN-05-L-T3-PQ2-VQ2-

System RQ2 RQ2
pressure
Degree of partial vacuum achieved (bar) Degree of partial vacuum achieved (bar)
1 bar -0.08 0
2 bar -0.34 -0.14
3 bar -0.54 -0.2
4 bar -0.7 -0.3
5 bar -0.77 -0.38
6 bar -0.8 -0.42

Drawing the partial vacuum curve
– Enter the characteristic curves of both vacuum generators for the degree of partial
vacuum achieved in the diagram below (pu = partial vacuum, p = system pressure).
Degree of partial vacuum achieved relative to operating pressure

Measuring evacuation time for both vacuum generators
Set up the circuit described above in accordance with the circuit diagram shown below. In
order to be able to compare the performance of the two vacuum generators included in
the equipment set, elapsed time is measured from the moment operating pressure (6
bar) is switched on until a defined degree of partial vacuum is reached.
Note:
The reservoir is required in order to ensure that the amount of time required for
evacuation is actually measurable, and thus simulates evacuation of a larger vacuum
system. Use a clock or a stopwatch to measure elapsed time.
1V3
+2 4 V 1 2 3 1 3
2
1Z2
13 12 14 22 24
1V2
S1 K1 K1
14 11 21
2
31
S2 1Z1
1 3
32
1V1 2
A1 1M 1
K1 1M 1 1 3
A2
0 V 12
11 14 .2
22
21 24 .3
32
31 34
42
41 44

– Measure evacuation time for all the listed values and enter the evacuation time for
both vacuum generators in the table included below. Set system pressure to 6 bar for
this exercise.
Partial Vacuum generator VN-05-H-T3-PQ2-VQ2- Vacuum generator VN-05-L-T3-PQ2-VQ2-

vacuum RQ2 RQ2
(bar) Evacuation time (s) Evacuation time (s)
-0.1 bar 0.4 -
-0.2 bar 0.8 0.4
-0.3 bar 1.0 0.8
-0.4 bar 1.8 2.0
-0.5 bar 2.4 Max. -0,44 bar
-0.6 bar 3.5
-0.7 bar 5.8
-0.8 bar 10.0
– Enter the determined evacuation times in the graphic shown below, and draw
characteristic curves for both vacuum generators.

Vacuum generator comparison
– Describe the differences between the two vacuum generators used and their
respective advantages for vacuum generation.
Vacuum generator VN-05-H-T3-PQ2-VQ2-RQ2:
This type of vacuum generator achieves a higher level of vacuum.

The maximum vacuum level is generated with low system pressure.
However, this vacuum generator requires significantly more evacuation time than
the other.
This type of vacuum generator should be used when the suction grippers require
greater holding forces, for example in order to reliably retain heavy loads.
Vacuum generator VN-05-L-T3-PQ2-VQ2-RQ2:
This vacuum generator achieves relatively low levels of vacuum in comparison with
the other
(approx. 50%).
High system pressure is required in order to reach maximum achievable vacuum.
On the other hand, it needs only minimal evacuation time in order to generate a
partial vacuum.
This vacuum generator is used when a large vacuum system has to be evacuated
quickly. Type L vacuum generators are used especially where minimal vacuum and/or
short cycle times are required.
Influences on vacuum generation
– Which other influences, in addition to changing system pressure and the size of the
system to be evacuated, might have negative effects on the generation of a partial
vacuum by means of a vacuum generator? Write them down.
Long or restricted tubing connections between the ejector and the suction cup.
Long or restricted compressed air supply line to the ejector.
Contaminated or clogged silencer.
Branch TEEs and angle connectors in the vacuum lines.

Influence of restrictions on vacuum generation
A flow control valve is installed in the respective line in order to simulate restrictions and
other unfavourable conditions in compressed air or vacuum lines. A restriction can then
be simulated by closing the flow control valve. Set the flow control valve to a specific
degree of restriction, and leave this setting unchanged for the entire duration of the
experiment.
– Simulate the influences listed in the table with regard to degree of partial vacuum and
evacuation time.
Influence Vacuum generator (type H) Vacuum generator (type L)
Contaminated silencer Evacuation time: Evacuation time:

Throttle point between the vacuum
generator and the silencer Max. vacuum Max. vacuum
Kink in the vacuum line between the If there’s a kink at either of these If there’s a kink at either of these
suction cup and the vacuum gauge, places, vacuum collapses at the places, vacuum collapses at the
and between the vacuum generator suction cup. However, if the kink suction cup. However, if the kink
and the vacuum gauge. is located between the vacuum is located between the vacuum
gauge and the suction cup, gauge and the suction cup,
vacuum is still indicated. vacuum is still indicated.
Restriction in the air supply line The smaller the throttle cross- The smaller the throttle cross-
Throttle point between the pressure section, the lower the degree of section, the lower the degree of
regulator or the directional control vacuum that can be achieved vacuum that can be achieved
valve and the vacuum generator
Restriction in the vacuum line The smaller the throttle cross- The smaller the throttle cross-
section, the lower the degree of section, the lower the degree of
Throttle point between ambient
vacuum that can be achieved vacuum that can be achieved
pressure and the vacuum generator
with vacuum gauge in-between.
Simulates a porous workpiece.
Measure evacuation time until the

maximum degree of partial vacuum is
achieved (with reservoir) with varying
vacuum line lengths.
15 seconds 3 seconds
10 cm
22 seconds 5 seconds
100 cm

Solution of exercise 2: Selecting suction cups for various workpieces
Selecting suction cups for various workpieces
Learning objectives
 You’ll be familiar with the effects of diameter on suction cup holding force.
 You’ll be able to select suitable suction cups for various workpieces.
 You’ll be familiar with the effects of workpiece surface on suction cup holding force.
Problem description
Various workpieces need to be transported with the planned handling unit. Different
suction cups will have to be used for these workpieces which have varying surface
finishes and shapes. You’ll need to test possibly suitable suction cups and select the best
one for each workpiece.
Parameters
 All the suction cups included with the equipment set should be tested on each of the
included workpieces.
 Use both the vacuum generators included with the equipment set.
Project assignment
1. Conduct a test series with all available suction cups and workpieces, and document
your results.
2. Evaluate your results.
3. Answer the questions.
4. Select the best possible suction cup for each workpiece.
5. Calculate the theoretical holding force of the various suction cups in combination with
different materials.

Circuit layout in accordance with the circuit diagram
– Complete the circuit diagram shown below, and set up the circuit for the test series.
Circuit diagram (solution)

Testing various suction cups with different workpieces
– Use the type L vacuum generator first, and grip each of the included workpieces with
all the suction cups. Measure the degree of partial vacuum generated in each case.
Grip the lid of the plastic can, as well as its side wall. Enter your results in the table
below.
Note
Use a system pressure of 6 bar, constant.
Suction Suction cup, Suction Suction Suction cup, Bellows, Suction

cup/workpiece cup, cup, 20 mm cup, oval
30 mm, 20 mm,
transparent 30 mm, 20 mm, transparent
black black
Sandpaper, 120 grit 0.3 0.38 0.14 0.24
Sandpaper, 180 grit 0.24 0.12 0.38 0.4 0.32 0.28
Plastic can, top 0.4 0.4 0.4 0.4 0.4 0.4
Plastic can, side wall 0.4 0.4*
Golf ball 0.4 0.4 0.4
Ball point pen 0.4*
Measurement results for type L vacuum generator
– Repeat the test with the type H vacuum generator. Enter your results in the table
below.
Suction Suction cup, Suction Suction Suction cup, Bellows, Suction

cup/workpiece cup, cup, 20 mm cup, oval
30 mm, 20 mm,
transparent 30 mm, 20 mm, transparent
black black
Sandpaper, 120 grit 0.54 0.6 0.3
Sandpaper, 180 grit 0.06 0.72 0.76 0.4 0.38
Plastic can, top 0.76 0.76 0.78 0.78 0.78 0.78
Plastic can, side wall 0.78 0.78
Golf ball 0.78 0.78 0.78
Ball point pen 0.78 0.76
Measurement results for type H vacuum generator

Suction cup selection
– Select the required vacuum generator for each workpiece, as well as the best suction
cup or suction cup type. Give reasons for you selection.
Workpiece Selected suction cup
Sand paper, 120 grit Suction cup, transparent, 20 mm. Together with the type L vacuum generator, this
suction cup reaches maximum possible vacuum with this workpiece.
Sand paper, 180 grit All the suction cups, except the bellows with 20 mm diameter, can be used in this
case. Partial vacuum of greater than -0.7 bar is achieved with the type H vacuum
generator.
Plastic can, top Maximum possible vacuum is achieved with all suction cups and all vacuum
generators.
Plastic can, side wall Only the bellows suction cup and the oval suction cup can be used in this case.
However, the workpieces have to be aligned along the longitudinal axis when the oval
suction cup is used. Either vacuum generator can be used, depending on the required
holding force.
Golf ball All suction cups with a diameter of 20 mm. Both vacuum generators.
Ball point pen Bellows suction cup and oval suction cup. Both vacuum generators.
Vacuum generator comparison
– What are the differences between the type L and type H vacuum generators with
regard to the degree of partial vacuum? Evaluate your measurements, make notes
about the differences and give reasons for them.
The type L vacuum generator produces a partial vacuum with 30 mm suction cups
on rough surfaces, whereas the type H vacuum generator does not produce any
measurable vacuum. The higher performance offered by the type L vacuum
generator makes it possible to generate greater degrees of partial vacuum on rough
surfaces.

Influence of surface finish on vacuum
– Make a note of the surfaces at which the gripping power of the suction cups is
greatest.
The gripping power of the suction cups is greatest on smooth, flat surfaces.
– Which pattern becomes apparent when the surface finishes of the workpieces are
considered in light of the degree of partial vacuum generated? Write your answer
down.
The rougher the surface, the weaker the vacuum generated relative to the
performance of the respective vacuum generator.
Differences between the suction cups with regard to diameter
– Consider the difference between 30 and 20 mm diameter suction cups with regard to
rough surfaces. Make a note of the difference you observe based on your
measurements.
In the case of rough surfaces, 20 mm suction cups always reach a greater degree of
vacuum than 30 mm suction cups, based on maximum vacuum for the respective
vacuum generator.
– Give a possible reason for this difference.
The smaller suction cups (including bellows and oval suction cups) have a smaller
circumference, thus reducing possible leakage due to unevenness at the edges of
the suction cup.

Suction cup performance with curved surfaces
– Consider the various suction cups with regard to curved surfaces (side wall of the
plastic can). Make a note of you conclusions.
Suction cups with smaller diameters are advantageous in this case, because the
workpieces have minimal diameters.
– Which type of suction cup is best suited for curved surfaces? Give reasons for you
selection.
A bellows suction cup is best suited, because it’s best able to adapt itself to the
curvature thanks to its bellows.
– Which restriction applies to the oval suction cup in this case?
It’s only capable of providing the required vacuum when it’s aligned to the
longitudinal axis of the curvature.
Influence of the material in the suction cup
– Compare the various suction cups with regard to the material from which they are
made.
On rough surfaces, the black suction cups achieve a lesser degree of vacuum than
the transparent suction cups.
The transparent suction cups are made of a more flexible material which is better
able to adapt itself to surface irregularities.
– What are the possible advantages of the black suction cups?
They have a longer service life due to the greater strength of the material used.

Checking suction cup selections
– Check the suction cup selections you made at the beginning of this exercise. Take the
results obtained from the above questions into consideration, and makes a note of
any possible restrictions.
Workpiece Possible restriction
Sandpaper, 120 grit No change
Sandpaper, 180 grit Due to its durability, the black suction cup should be given preference to the
transparent one.
Plastic can, top The black suction cup can be used due to its long service life.
Plastic can, side wall The bellows suction cup should be used in this case, because it eliminates the need for
alignment with the workpiece.
Golf ball A black suction cup should be used due to its long service life.
Ball point pen Preference should be given to the oval suction cup in this case, because it’s capable of
gripping the narrower end of the pen.

Calculating theoretically required suction cup diameter for a specified load
A workpiece with a weight of 22.5 kg and a smooth, flat surface needs to be lifted with a
suction cup.
The equation for Earth’s gravitational force and the formula for the holding force of a
round suction cup:
p
g = d2 � �
F = m� pU
4
are rewritten as follows:
m�g
d2 =
p
�
pU
4 m
And thus the required diameter (in metres) amounts to:
m�g
d=
p
�
p
4 U m
The following values are known for the individual parameters:
pU = partial vacuum of 78,000 Pa

m = load of 22.5 kg
g = acceleration due to gravity of 9.81 m/s2
d = effective diameter of the suction cup in metres

– Calculate the required suction cup diameter.
m m
22.5 kg �
9.81 22.5 kg �
9.81 2
2
s = s 22.5 �9.81
d= = m
0.785 �
78, 000 Pa kg m 0.785 �78, 000
0.785 �
78,000 2 2
s m
220.725
d= m
61,230
d = 0.00360 m
d = 0.06 m
This corresponds to a suction cup diameter of 60 mm.
Suction cup selection criteria
– Write down the results of your examinations and summarise them. Take the
workpiece’s surface finish and shape, suction cup diameter and flexibility of the
suction cup material into consideration.
With unchanging partial vacuum, the achievable holding force increases along with
suction cup diameter. Suction cup surface area and holding force are proportional to
each other.
The softest possible suction cups are used for workpieces with rough surfaces.
The rougher the surface, the lesser the degree of partial vacuum that can be
achieved.


Maintaining vacuum when using more than one suction cup
Learning objectives
 You’ll be familiar with the methods for maintaining vacuum in the event that, when
using several suction cups, not all of them retain their grip.
 You’ll be able to grip workpieces without flat surfaces using vacuum grippers.
Problem description
A workpiece will be gripped using two suction cups. It is possible that only one of the two
suction cups grips the workpiece and the other doesn’t, for example because it isn’t
placed squarely onto the surface. As a result, no partial vacuum is generated at the first
suction cup either.
Parameters
 Both suction cups are supplied with partial vacuum from a single vacuum generator.
 The bellows suction cup will be used.
Project assignment
1. Specify the requirements for the vacuum system.
2. Locate a point within the vacuum system at which vacuum can be monitored.
3. Decide which components will be required and describe their functions.
4. Draw the pneumatic circuit diagram.
5. Set up the circuit and test it to check if it meets the required function.

Solution of exercise 3: Maintaining vacuum when using more than one suction cup
Selection of required components

When two or more suction cups are supplied with partial vacuum from a single vacuum
generator, it may be that one of the suction cups does not grip the workpiece.
Consequently, no partial vacuum, and thus no holding force, can be generated.
– Which requirements apply to maintaining vacuum under the conditions described

above? Write your answer down.
Any generation of inadequate partial vacuum at the suction cup must be detected.
The vacuum line of the affected suction cup must be sealed off, in order to ensure
that partial vacuum is generated at the other suction cups.
– Where within the vacuum system must these requirements be tested? Give reasons
for you selection.
Whether or not the required partial vacuum is being generated can only be
determined directly at the individual suction cups. At all other points within the
system it’s only possible to determine that too little partial vacuum exists, but not at
which suction cup the leak is occurring.

Component selection
– Name the components illustrated below, and describe their design and function.
The required component is a vacuum security valve.
Vacuum security valves are installed between the vacuum generator and the suction
cup. If, during vacuum generation, a suction cup is uncovered, or only partly
covered, the vacuum security valve automatically stops the influx of air almost
entirely.
A soon as the suction cup is once again fitted tightly against the surface, vacuum is
regenerated. Removal of the workpiece from the suction cup also causes the
vacuum security valve to immediately close almost entirely.
If the suction cup is open to the environment, a float in the vacuum security valve is
pressed up against the housing. In this position, flow is only possible through a small
hole in the float. When a workpiece is in contact with the suction cup, air flow is
reduced and the spring forces the float forward. The vacuum security valve is thus
opened and full vacuum is generated within the suction cup.

Creating the equipment list
– Think about which components you’ll need in order to set up the circuit, and enter
them in the table below.
Quantity Designation
2 Suction cup, bellows
1 Barbed Y-connector
1 Barbed T-connector
1 Vacuum gauge
1 Vacuum generator, type L
1 Vacuum generator, type H
1 3/2-way solenoid valve, normally closed (from TP 201)
1 Relay, 3-way (from TP 201)
1 Signal input, electrical (from TP 201)
1 Distributor block (from TP 201)
1 On-off valve with filter-regulator (from TP 201)
1 Compressed air source
Equipment list

Completing the pneumatic circuit diagram
– Complete the circuit diagram below.
Pneumatic circuit diagram (solution)

Electrical circuit diagram
– Set up the electrical circuit on the basis of your equipment list and the circuit diagram
shown below.
+2 4 V 1 2 3
13 12 14 22 24
S1 K1 K1
14 11 21
31
S2
32
A1
K1 1M 1
A2
0 V 12
11 14 .2
22
21 24 .3
32
31 34
42
41 44
Electrical circuit diagram

Checking for correct functioning
Set up the controller and test it for correct functioning in accordance with the
requirement. To do this, measure the degree of partial vacuum in various cases.
– Enter your measurement results in the tables included below. Make a note of the
conclusions you arrive at based on these measurement results.
Note
Set system pressure to 6 bar. Carry out the measurement with and without the vacuum
security valve.
Vacuum generation on, none of the suction cups grips the workpiece
Vacuum generator Partial vacuum achieved Partial vacuum achieved

(type) without vacuum security valve with vacuum security valve
Type H 0 -0.42
Type L 0 -0.32
Vacuum generation on, one suction cup grips the workpiece

Type H 0 -0.56
Type L 0 -0.36
Vacuum generation on, both suction cups grip the workpiece

Type H -0.78 -0.78
Type L -0.42 -0.42
Conclusions: When vacuum security valves are used, adequate partial vacuum is
generated even if individual suction cups do not grip the workpiece (approx. 65% of
achievable partial vacuum). In contrast to this, adequate partial vacuum is not
available when vacuum security valves are not used.

Advantages of vacuum security valves
– Which advantages do vacuum security valves offer, and where can they be used?
When a workpiece becomes dislodged from one suction cup partial vacuum doesn’t
collapse at the others, which are connected to the same vacuum generator. If one
suction cup is not in contact with the workpiece, only a small portion of the partial
vacuum is lost.
Workpieces with wavy or stepped surfaces can still be gripped, even if one of the
suction cups doesn’t make full contact with the workpiece surface.

Monitoring partial vacuum
Learning objectives
 You’ll be able to monitor partial vacuum with a pressure switch.
 You’ll be able to perform this type of monitoring under various conditions.
Problem description
A handling unit needs to move workpieces from a conveyor belt to a roller container. It
must be ensured that none of the workpieces is dropped during transport due to
inadequate partial vacuum. The handling unit should not be started until enough partial
vacuum has been built up. The vacuum level therefore has to be checked to determine
whether or not the required level has been reached. This should be done automatically.
When the required degree of partial vacuum has been reached, a signal lamp indicates
that the handling device can be started manually.
Parameters
 The following stipulations should be observed:
 The type H vacuum generator must be used.
 The following situations must be taken into consideration:
At least one suction cup must grip, for example at > -0.5 bar.
All suction cups must grip, for example at > -0.6 bar.
Project assignment
1. Stipulate the conditions for monitoring partial vacuum.
2. Answer the questions concerning the mode of operation and adjustment of the
vacuum switch.
3. Gather the required components.
4. Set up the circuit.
5. Test the circuit for correct functioning.

Solution of exercise 4: Monitoring partial vacuum
Conditions for monitoring partial vacuum
– Think about which conditions have to be fulfilled in order to monitor a specific partial
vacuum value. Make use of the results of your previous measurements to this end.
Write your conditions down.
You need to know how much partial vacuum is required in order to retain the
workpiece.
An adjustable pressure switch must be used.
Questions concerning the vacuum switch
– Describe the mode of operation of the vacuum switch included in the equipment set.
The vacuum switch used is designed as a switch. The output is switched when the
specified partial vacuum value is reached. It covers a pressure range of 0 to -1 bar
and is infinitely adjustable over the entire range.
– Match up the vacuum switch’s terminal designations with the correct functions.
Terminal designation Function
1 Positive supply voltage
3 Negative supply voltage
4 Switching output
Terminal designations for sensors

– The connecting cables of proximity switches are colour coded. Enter the correct colour
abbreviations for the connecting cables in the table.
Connection Colour abbreviation
Operating voltage, positive terminal BN (RD)
Operating voltage, negative terminal BU
Switching output BK
Sensors with 3 connecting cables
Training notes
The switching output always has a black connecting cables, regardless of function (NO
or NC).
– The vacuum switch must be set to the required value. Describe how the vacuum
switch is adjusted.
In order to adjust the vacuum switch, the required degree of partial vacuum must
first of all be generated. This is done by setting system pressure such that the
required degree of partial vacuum is reached.
Once the required degree of partial vacuum has been reached, the EDIT key on the
vacuum switch is pressed and held until the integrated LED blinks. When the key is
released, the vacuum switch saves the momentary partial vacuum value to memory
as a switching pressure.

Creating the equipment list
– Think about which components you’ll need in order to set up the circuit, and enter
them in the table included below.
1 3/2-way solenoid valve
1 Vacuum generator
2 Vacuum security valve
1 Barbed Y-connector
1 Barbed T-connector
2 Suction cup
1 Vacuum switch
1 Distributor block
1 On-off valve with filter-regulator
1 Compressed air source
Equipment list

Drawing the pneumatic circuit diagram
– Complete the pneumatic circuit diagram.

Drawing the electrical circuit diagram
– Complete the electrical circuit diagram.
Electrical circuit diagram (solution)

Setting up the controller and describing its mode of operation
Set up the controller and test it for correct functioning in accordance with the stipulated
conditions.
– Describe the mode of operation, and how it can be checked for correct functioning.
When switch S1 is actuated, valve 1V1 is switched and opens compressed air supply
to the vacuum generator. Vacuum generation is started.
When partial pressure reaches the required value, the vacuum switch is switched
and the signal lamp lights up.
A vacuum gauge is installed in the vacuum line in order to check for correct
switching pressure. Partial vacuum is read at the moment the vacuum switch is
switched, and is compared with the specified partial vacuum value.


Reducing compressed air consumption in a vacuum system
Learning objectives
 You’ll be able to set up a circuit which makes it possible to minimise compressed air
consumption in a vacuum system.
 You’ll be able to calculate cost savings and amortisation time for compressed air
economy circuits.
Definition of the problem

Golf balls need to be moved from a container to a gravity-feed magazine in order to fill
them into retail packaging.
Project assignment
1. Specify the requirements for the stipulated circuit.
2. Gather the required components.
3. Complete the equipment list.
4. Complete the electrical and pneumatic circuit diagrams.

Solution of exercise 5: Reducing compressed air consumption in a vacuum system
Controller requirements
– Specify the requirements for the stipulated controller.
When partial pressure at the suction cup reaches the specified value, vacuum
generation must be stopped, i.e. no more compressed air can be fed to the ejector.
When partial pressure at the suction cup falls below a specified value, vacuum is
generated again until the required vacuum level has been reached.
Selecting suitable components and determining the installation location
In order to save compressed air, the compressed air supply to the vacuum generator is
stopped as long as the vacuum doesn’t fall below a specified value. However, vacuum
pressure drops off very quickly.
How can the time span during which supply is stopped be increased, and where must
vacuum be monitored?
– Name a component which prevents vacuum pressure from dropping off, and describe
its necessity and function.
Vacuum pressure drops off because atmospheric air flows into the vacuum system
via the ejector’s exhaust port.
A non-return valve is installed in the vacuum line in order to prevent this and retain
vacuum pressure. In this way, vacuum pressure is only lost due to possible leaks at
the suction cup.
Partial vacuum must be monitored between the non-return valve and the suction
cup.

Calculating cost savings which result from the compressed air economy circuit
– Calculating daily monetary savings which result from the compressed air economy
circuit
The following facts are known:

Compressed air costs: €0.15 per m3
Flow rate of a type H vacuum generator with an operating pressure of 6 bar: 12 l/min
The lifting device is operated 8 hours a day.
The vacuum generator is operated 50% of the time (load stroke).
Compressed air savings amount to approx. 40% per load stroke.
Compressed air consumption per day in minutes:

8 hours x 60 = 480 minutes
Vacuum generator operating time = 480 ÷ 2 = 240 minutes
Consumed compressed air = 240 minutes x 12 litres per minute = 2880 litres
Costs for consumed compressed air = 2.88 m3 x €0.15 = €0.43
Cost reduction resulting from the compressed air economy circuit = €0.43 x 0.4 =
€0.17
Daily costs are thus reduced to €0.26.
– Calculate the compressed air cost savings for a facility at which 12 of these lifting
devices are used 320 days a year on average. Calculate the costs for 3-shift operation
as well.
Enter your results in the table below.
Costs (€) Costs with economy

Savings per year (€)
circuit (€)
1 lifting device, per year 137.60 83.20 54.00
12 lifting devices, per year 1651.20 998.40 652.80
3-shift operation with 12

4953.60 2995.20 1958.40
lifting devices, per year
– Calculate amortisation time in days if

the pressure switch costs €57.30,
the non-return valve costs €12.70 and
assembly costs amount to €20.00.
Total costs per lifting device: €90.00

Savings per day: €0.17
Amortisation after: 529 days


Component selection
– Compile an equipment list for the required controller and enter the components in the
table below.
1 Barbed T-connector (from TP 201)
1 Non-return valve
1 Vacuum generator unit (soft)
1 Vacuum generator (H)
1 Vacuum switch
1 Compressed air source (from TP 201)
Equipment list

Drawing the pneumatic circuit diagram
– Complete the circuit diagram by adding the required components.

Drawing the electrical circuit diagram
– Draw the electrical circuit diagram for the compressed air economy circuit.

Controlled release of workpieces retained by a vacuum
Learning objectives
 You’ll be able to release workpieces from the suction gripper in a controlled fashion
after transport has been completed using a compressed air economy circuit.
Parameters
Use the compressed air economy circuit from exercise 5.
Project assignment
1. Specify the requirements for the stipulated circuit.
2. Complete the electrical and pneumatic circuit diagrams.
4. Optimise your circuit.

Solution of exercise 6: Controlled release of workpieces retained by a vacuum
Determining controller requirements
If a workpiece has been gripped using a compressed air economy circuit, and if there’s no
leak between the suction cup and the workpiece, the workpiece is retained due to
confined vacuum pressure. The vacuum must thus be evened out in a controlled fashion
in order to ensure that the workpiece is released from the suction cup.
– Describe how this can be done.
A short compressed air pulse is applied to the suction cup. This compressed air pulse
results in controlled, reliable and quick release of the workpiece from the suction
cup.
Complete the equipment list
– Adapt the equipment list to meet the requirements you have determined.
1 Barbed X-connector
1 Non-return valve
1 Vacuum generator unit (soft)
1 Vacuum generator (H)
1 Vacuum switch
1 Compressed air source (from TP 201)
Equipment list

Expanding the pneumatic circuit diagram
– Expand the pneumatic circuit diagram for the compressed air economy circuit to
include the components you have determined will be required, as well as the
associated tubing.

Expanding the compressed air economy circuit
– Expand the electrical circuit diagram for the compressed air economy circuit to
include the components you have determined will be required, as well as the
associated wiring.

Optimising the ejection function
The workpiece is ejected with full system pressure. This may mean that, in the case of
lightweight workpieces, the workpiece might not be set down at the specified location, or
it may be damaged.
– How can you make sure that lightweight or fragile workpieces are set down carefully?
The volumetric flow rate and thus the strength of the ejector pulse can be adapted
to the respective workpiece and suction cup by using an adjustable restrictor.
The further the restrictor is closed, the more gently the workpiece is released.
– What do you have to take into consideration when the system is operated without a
compressed air economy circuit?
If the compressed air economy circuit is not used, the ejector pulse must be strong
enough to ensure that the workpiece is released even when vacuum is being
generated. The volumetric flow rate for the ejector pulse must be greater that the
suction rate.


Solutions of Exercises PN381 00137360001303911569

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Vacuum technology – Fundamentals

2 © Festo Didactic GmbH & Co. KG

© Festo Didactic GmbH & Co. KG 3

Solution of exercise 1: Generating vacuum 4

© Festo Didactic GmbH & Co. KG 4

© Festo Didactic GmbH & Co. KG 5

Mode of operation of a vacuum generator based on the venturi principle

6 © Festo Didactic GmbH & Co. KG

Measuring the degree of partial vacuum generated with various vacuum

– Enter the acquired values in the table below.

Vacuum generator VN-05-H-T3-PQ2-VQ2- Vacuum generator VN-05-L-T3-PQ2-VQ2-

2 bar -0.34 -0.14

3 bar -0.54 -0.2

4 bar -0.7 -0.3

5 bar -0.77 -0.38

6 bar -0.8 -0.42

© Festo Didactic GmbH & Co. KG 7

Drawing the partial vacuum curve

Degree of partial vacuum achieved relative to operating pressure

8 © Festo Didactic GmbH & Co. KG

Measuring evacuation time for both vacuum generators

© Festo Didactic GmbH & Co. KG 9

Partial Vacuum generator VN-05-H-T3-PQ2-VQ2- Vacuum generator VN-05-L-T3-PQ2-VQ2-

-0.1 bar 0.4 -

-0.2 bar 0.8 0.4

-0.3 bar 1.0 0.8

-0.4 bar 1.8 2.0

-0.5 bar 2.4 Max. -0,44 bar

-0.6 bar 3.5

-0.7 bar 5.8

-0.8 bar 10.0

10 © Festo Didactic GmbH & Co. KG

Vacuum generator comparison

Vacuum generator VN-05-H-T3-PQ2-VQ2-RQ2:

This type of vacuum generator achieves a higher level of vacuum.

Vacuum generator VN-05-L-T3-PQ2-VQ2-RQ2:

Influences on vacuum generation

© Festo Didactic GmbH & Co. KG 11

Influence of restrictions on vacuum generation

Influence Vacuum generator (type H) Vacuum generator (type L)

Contaminated silencer Evacuation time: Evacuation time:

Measure evacuation time until the

12 © Festo Didactic GmbH & Co. KG

13 © Festo Didactic GmbH & Co. KG

Circuit layout in accordance with the circuit diagram

Circuit diagram (solution)

14 © Festo Didactic GmbH & Co. KG

Testing various suction cups with different workpieces

Suction Suction cup, Suction Suction Suction cup, Bellows, Suction

Sandpaper, 120 grit 0.3 0.38 0.14 0.24

Sandpaper, 180 grit 0.24 0.12 0.38 0.4 0.32 0.28

Plastic can, top 0.4 0.4 0.4 0.4 0.4 0.4

Plastic can, side wall 0.4 0.4*

Golf ball 0.4 0.4 0.4

Ball point pen 0.4*

Measurement results for type L vacuum generator

Suction Suction cup, Suction Suction Suction cup, Bellows, Suction

Sandpaper, 120 grit 0.54 0.6 0.3

Sandpaper, 180 grit 0.06 0.72 0.76 0.4 0.38

Plastic can, top 0.76 0.76 0.78 0.78 0.78 0.78

Plastic can, side wall 0.78 0.78

Golf ball 0.78 0.78 0.78

Ball point pen 0.78 0.76